Advanced_Manufacturing_Material_Addition_Process.pptx

3D printing

1. Advanced Manufacturing Techniques – Material Addition Process 3D Printing Technologies: SLA, SLS, FDM, LOM, LENS, and LIGA Prepared by Dr. Abhilash S S Assistant Professor, Dept. of Mechanical Engineering SCT College of Engineering, Pappanamcode

2. Introduction to Additive Manufacturing Additive Manufacturing (AM), commonly known as 3D Printing, is a process of creating a 3D object layer by layer from a digital model. It contrasts with subtractive manufacturing which removes material. Applications include prototyping, tooling, and direct part production.

3. Material Addition Processes 1. Stereo-lithography (SLA) 2. Selective Laser Sintering (SLS) 3. Fused Deposition Modelling (FDM) 4. Laminated Object Manufacturing (LOM) 5. Laser Engineered Net Shaping (LENS) 6. LIGA Process Each method uses different energy sources and materials.

4. Stereo-lithography (SLA) • Uses UV laser to cure photosensitive resin layer by layer. • High accuracy and surface finish. • Ideal for prototypes and casting patterns. Advantages: - Excellent resolution - Smooth surface finish Limitations: - Limited material options - Expensive resin.

5. Selective Laser Sintering (SLS) • Uses laser to sinter powdered material (nylon, metal, etc.) layer by layer. • No support structure needed as powder acts as support. Advantages: - Strong functional parts - Wide material range Limitations: - Rough surface finish - Post-processing required.

6. Fused Deposition Modelling (FDM) • Thermoplastic filament (ABS, PLA) is heated and extruded through a nozzle. • Deposited layer by layer on a build platform. Advantages: - Low cost - Easy to operate Limitations: - Visible layer lines - Limited to thermoplastics.

7. Laminated Object Manufacturing (LOM) • Layers of paper, plastic, or metal laminates are bonded and cut to shape. • Laser or blade cutting used. Advantages: - Low material cost - Suitable for large models Limitations: - Poor dimensional accuracy - Weak inter-layer bonding.

8. Laser Engineered Net Shaping (LENS) • Uses high-power laser to melt metallic powder directly onto substrate. • Powder delivered via nozzle synchronized with laser path. Advantages: - Suitable for metal repair - High strength parts Limitations: - Complex system - Surface finish requires machining.

9. LIGA Process • German acronym: Lithographie, Galvanoformung, Abformung (Lithography, Electroforming, Molding) • Uses deep X-ray lithography to create microstructures. Advantages: - High aspect ratio microcomponents - Suitable for MEMS Limitations: - Expensive equipment - Limited materials.

10. Comparison of Additive Manufacturing Processes SLA – High accuracy, photopolymer resin SLS – Powder-based, strong parts FDM – Low cost, thermoplastics LOM – Laminated sheets LENS – Metal powder, high precision LIGA – Microfabrication, MEMS.

11. Applications of 3D Printing • Aerospace: Lightweight structural components • Automotive: Rapid prototyping and tooling • Medical: Customized implants and prosthetics • Consumer Goods: Product design and models • Research and Education: Concept visualization.

12. Future Trends in Additive Manufacturing • Multi-material 3D printing • Integration with AI and IoT • Bioprinting of tissues and organs • Sustainable and recyclable materials • On-demand spare part manufacturing.

13. Conclusion Additive Manufacturing revolutionizes modern manufacturing by enabling complex geometries, customization, and rapid prototyping. Understanding each process helps in selecting the right technology for specific applications.